Crystalline forms of morphine sulfate

ABSTRACT

The present disclosure is directed to crystalline forms of morphine sulfate and pharmaceutical compositions comprising any of the crystalline forms of morphine sulfate. Also provided are processes for the preparation of crystalline forms of morphine sulfate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 14/670,493, filed Mar. 27, 2015, the disclosures of which are incorporated herein by reference in their entireties for all purposes.

FIELD OF THE INVENTION

The present disclosure relates to crystalline forms of morphine sulfate, and methods for making the same. The present disclosure also relates to pharmaceutical compositions containing morphine sulfate and methods for treating pain using such compositions.

BACKGROUND OF THE INVENTION

Morphine is the most abundant of at least 50 alkaloids found in opium, poppy and poppy derivatives, Papaver somniferum. Poppy straw is opium poppy (Poppy somniferum) that is harvested when fully mature and dry, minus the ripe poppy seeds. An agricultural by-product of the poppy seed harvest, the straw was a waste product before the 1930s when a chemical process became available to extract morphine from it. Poppy straw consisting mainly of the capsule became a valuable source of morphine. Today, poppy straw is a major source of many opioids and other alkaloids. It is the source of 90% of the world supply of legal morphine (i.e. for medical and scientific use).

During processing, poppy straw is pulverized and washed many times in water and/or various acids and other chemicals to produce poppy straw concentrate (PSC) or concentrated poppy straw (CPS). Once dried, the concentrate is a beige to brown colored powder and contains salts of various alkaloids. It can range from about 9 to 30 times the morphine concentration of poppy straw. Morphine is generally 8% to 17% of the dry weight of opium, although specially-designed cultivars reach 26% or produce little morphine at all. The latter varieties, including the Przemko and Norman strains of the opium poppy, are used to produce two other alkaloids, thebaine and oripavine, which are used in the manufacture of semi-synthetic opioids like oxycodone and etorphine as well as other types of drugs. At least one manufacturer, Tasmanian Alkaloids, produces both high-morphine and high-thebaine/oripavine types of CPS.

Morphine is produced most predominantly early in the life cycle of the plant and, past the optimum point for extraction, various processes in the plant produce codeine, thebaine, and in some cases low quantities of hydromorphone, dihydromorphine, dihydrocodeine, tetrahydrothebaine and hydrocodone.

Morphine, generally administered in a salt form, is a potent opiate analgesic, for the relief of moderate to severe pain, and has been approved for use for decades. It can be administered as an injectable solution, suppository, capsule, tablet or extended release product. Like other opioids, e.g. oxycodone, hydromorphone and diacetylmorphine (heroin), morphine acts directly on the central nervous system (CNS) to relieve pain. Today, morphine sulfate is sold under various trade names including Astramorph PF™, Avinza®, DepoDur®, Duramorph, Infumorph, Kadian®, MS-Contin®, Oramorph® SR and RMS. Kadian® is a morphine sustained-release dosage form for once or twice per day dosing. Kadian® is currently available in 10, 20, 30, 40, 50, 60, 80, 100 and 200 mg morphine sulfate extended release capsules.

Morphine is regarded as the opioid drug of choice in the treatment of cancer pain, for example. Side effects of morphine treatment include, for example, nausea and vomiting, constipation, sedation, confusion and loss of appetite. It has been suggested that the use of modified release morphine formulations, apart from their convenience and their ability to provide continuous analgesia, may also result in a lower incidence and severity of morphine-related side effects. Sustained-release morphine dosage forms are described in U.S. Pat. Nos. 5,202,128, 5,215,758, 5,378,474 and 5,672,360.

All references cited herein, including the morphine sulfate products associated with the above-mentioned trade names, are incorporated herein by reference in their entireties.

SUMMARY OF THE INVENTION

The present disclosure is directed to eight novel crystalline forms of morphine sulfate. These forms are identified herein as Forms α, β, γ, δ, ε, ζ, η and θ. The present disclosure is further directed to processes for the preparation of the crystalline forms of morphine sulfate as herein described.

Illustrative of the present disclosure is a pharmaceutical composition comprising at least one pharmaceutically acceptable excipient and any of the crystalline forms of morphine sulfate as herein described. An illustration of the present disclosure is a pharmaceutical composition made by mixing any of the crystalline forms of morphine sulfate as herein described and at least one pharmaceutically acceptable excipient. Illustrating the present disclosure is a process for making a pharmaceutical composition comprising mixing any of the crystalline forms of morphine sulfate as herein described and at least one pharmaceutically acceptable excipient.

Exemplifying the present disclosure are methods of treating pain, comprising administering to a subject in need thereof, one or more of the morphine sulfate crystalline forms or pharmaceutical compositions described above.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an X-ray powder diffractogram of morphine free base, expressed in terms of ° 2θ.

FIG. 2 is an X-ray powder diffractogram of morphine sulfate crystalline Form α, expressed in terms of ° 2θ.

FIG. 3 is an X-ray powder diffractogram of morphine sulfate crystalline Form β, expressed in terms of ° 2θ.

FIG. 4 is an X-ray powder diffractogram of morphine sulfate crystalline Form γ, expressed in terms of ° 2θ.

FIG. 5 is an X-ray powder diffractogram of morphine sulfate crystalline Form δ, expressed in terms of ° 2θ.

FIG. 6 is an X-ray powder diffractogram of morphine sulfate crystalline Form ε, expressed in terms of ° 2θ.

FIG. 7 is an X-ray powder diffractogram of morphine sulfate crystalline Form ζ, expressed in terms of ° 2θ.

FIG. 8 is an X-ray powder diffractogram of morphine sulfate crystalline Form η, expressed in terms of ° 2θ.

FIG. 9 is an X-ray powder diffractogram of morphine sulfate crystalline Form θ, expressed in terms of ° 2θ.

FIG. 10 is a measured differential scanning calorimetry thermogram of morphine free base.

FIG. 11 is a measured differential scanning calorimetry thermogram of morphine sulfate crystalline Form α.

FIG. 12 is a measured differential scanning calorimetry thermogram of morphine sulfate crystalline Form β.

FIG. 13 is a measured differential scanning calorimetry thermogram of morphine sulfate crystalline Form γ.

FIG. 14 is a measured differential scanning calorimetry thermogram of morphine sulfate crystalline Form δ.

FIG. 15 is a measured differential scanning calorimetry thermogram of morphine sulfate crystalline Form ε.

FIG. 16 is a measured differential scanning calorimetry thermogram of morphine sulfate crystalline Form ζ.

FIG. 17 is a measured differential scanning calorimetry thermogram of morphine sulfate crystalline Form η.

FIG. 18 is a measured differential scanning calorimetry thermogram of morphine sulfate crystalline Form θ.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure is directed to eight novel crystalline forms of morphine sulfate, as herein described in detail. More particularly, the present disclosure is directed to novel crystalline Forms α, β, γ, δ, ε, ζ, η and θ of morphine sulfate.

The present disclosure is further directed to processes for the preparation of the crystalline forms of morphine sulfate, as described in more detail in the Examples which follow herein.

The present disclosure is further directed to pharmaceutical compositions comprising one or more of the crystalline forms of morphine sulfate. The present disclosure is further directed to a method of treating pain comprising administering to a subject in need thereof, one or more of the forms of morphine sulfate.

The term “composition” as used herein is intended to encompass a product comprising the specified ingredients in the specified amounts, as well as any product which results, directly or indirectly, from combinations of the specified ingredients in the specified amounts.

The term “excipient” as used herein refers to a pharmaceutically acceptable organic or inorganic carrier substance. Excipients may be natural or synthetic substances formulated alongside the active ingredient of a medication, included for the purpose of bulking-up formulations that contain potent active ingredients (thus often referred to as “bulking agents,” “fillers,” or “diluents”), or to confer a therapeutic enhancement on the active ingredient in the final dosage form, such as facilitating drug absorption or solubility. Excipients can also be useful in the manufacturing process, to aid in the handling of the active substance, such as by facilitating powder flowability or non-stick properties, in addition to aiding in vitro stability such as prevention of denaturation over the expected shelf life.

The term “subject” as used herein refers to an animal, preferably a mammal, most preferably a human, who has been the object of treatment, observation or experiment. Preferably, the subject has experienced and/or exhibited at least one symptom of the disease or disorder to be treated and/or prevented. Further, a subject may not have exhibited any symptoms of the disorder, disease or condition to be treated and/prevented, but has been deemed by a physician, clinician or other medical professional to be at risk for developing said disorder, disease or condition.

The terms “treating,” “treatment” and the like as used herein shall include the management and care of a subject (preferably a mammal, more preferably a human) for the purpose of combating a disease, condition, or disorder and includes the administration of a compound of the present disclosure to prevent the onset of the symptoms or complications, alleviate the symptoms or complications, or eliminate the disease, condition, or disorder.

The crystalline forms of morphine sulfate of the present disclosure may be prepared directly or indirectly from morphine free base. Examples 1-10, which follow herein, provide embodiments of the preparation of the crystalline forms of morphine sulfate.

The crystalline forms of morphine sulfate herein described may be characterized by one or more of their characteristic physical properties including, but not limited to, X-ray powder diffraction peaks and differential scanning calorimetry.

The crystalline forms of morphine sulfate may be identified by their X-ray powder diffraction peaks/pattern. X-ray powder diffraction analysis on representative samples of the crystalline forms of morphine sulfate as herein described is performed using a Bruker D8 Advance instrument equipped with a Cu Kα radiation source (1.54° Angstrom), a 9-position sample holder and a LYNXEYE™ Super Speed Detector. Samples are placed on zero-background, silicon plate holders.

One skilled in the art would recognize that the ° 2θ values and the relative intensity values are generated by performing a peak search on the measured data and the d-spacing values are calculated by the instrument from the ° 2θ values using Bragg's equation. One skilled in the art would further recognize that the relative intensity for the measured peaks may vary as a result of sample preparation, orientation and instrument used, for example. A variation of about ±0.2 is not atypical in obtainable 2θ values.

Morphine sulfate Form α is a unique crystalline phase. Morphine sulfate Form α may be characterized as a white to off-white powder. Morphine sulfate Form α is further characterized by its X-ray powder diffraction pattern peaks and/or d-spacing values, as listed in Table 1 below. FIG. 2 is a representative X-ray powder diffractogram for a representative sample of morphine sulfate Form α made according to Examples 3 and 4.

TABLE 1 XRPD peak list of Form α 2θ d spacing, A° Count % 7.54 11.721 7785 4.3 8.61 10.268 38031 21.1 9.49 9.312 12778 7.1 9.85 8.973 7574 4.2 10.49 8.429 8583 4.8 12.07 7.328 33865 18.7 12.72 6.954 32689 18.1 13.14 6.735 24265 13.4 13.45 6.576 127441 70.6 13.81 6.405 116666 64.6 14.45 6.125 102448 56.7 14.98 5.908 39629 21.9 15.48 5.721 123015 68.1 15.71 5.635 180619 100 16.32 5.429 61348 34 16.53 5.360 41019 22.7 17.08 5.187 163643 90.6 17.63 5.026 134116 74.3 17.86 4.964 97291 53.9 18.78 4.721 13223 7.3 19.36 4.581 32796 18.2 19.69 4.506 20822 11.5 20.20 4.394 65519 36.3 20.71 4.286 115491 63.9 21.19 4.190 57204 31.7 22.03 4.032 10157 5.6 22.94 3.874 46005 25.5 23.63 3.762 18021 10 24.24 3.669 82081 45.4 24.88 3.575 50940 28.2 25.32 3.514 38533 21.3 25.69 3.466 57300 31.7 26.22 3.396 63972 35.4 26.70 3.336 23001 12.7 27.09 3.289 33408 18.5 27.55 3.235 18065 10 28.12 3.171 21428 11.9 28.59 3.120 23902 13.2 28.94 3.083 17979 10 29.37 3.039 27704 15.3 30.17 2.960 21079 11.7 30.93 2.889 14141 7.8 31.54 2.834 11195 6.2 32.27 2.772 17448 9.7 33.212 2.69534 11463 6.3 33.974 2.63664 10917 6 34.293 2.61282 12547 6.9 35.837 2.50371 10904 6 36.722 2.4454 16439 9.1 37.636 2.38808 11620 6.4 37.839 2.37569 11178 6.2 39.62 2.27295 7555 4.2

Morphine sulfate Form β is a unique crystalline phase. Morphine sulfate Form β may be characterized as a white to off-white powder. Morphine sulfate Form β is further characterized by its X-ray powder diffraction pattern peaks and/or d-spacing values, as listed in Table 2 below. FIG. 3 is a representative X-ray powder diffractogram for a representative sample of morphine sulfate Form β made according to Example 5.

TABLE 2 XRPD peak list of Form β 2θ d spacing, A° Count % 5.21 16.962 9073 5 8.56 10.322 26160 14.5 12.36 7.156 18702 10.4 12.60 7.020 23369 12.9 13.68 6.468 80427 44.5 14.32 6.178 49082 27.2 14.52 6.094 33095 18.3 15.43 5.738 180661 100 16.42 5.394 35816 19.8 16.89 5.246 68594 38 17.78 4.984 82044 45.4 18.55 4.779 8643 4.8 19.26 4.605 22015 12.2 19.72 4.499 15094 8.4 20.14 4.406 49433 27.4 20.58 4.313 50985 28.2 21.08 4.212 37666 20.8 21.67 4.097 10205 5.6 22.87 3.886 31679 17.5 23.98 3.709 31482 17.4 24.34 3.653 49142 27.2 24.69 3.603 35649 19.7 25.34 3.512 14993 8.3 25.78 3.453 48874 27.1 26.13 3.407 26087 14.4 26.68 3.339 33491 18.5 27.58 3.232 11169 6.2 27.99 3.185 13749 7.6 28.43 3.136 12380 6.9 28.75 3.102 11857 6.6 29.25 3.051 21413 11.9 29.81 2.995 10374 5.7 30.75 2.906 11393 6.3 31.50 2.837 8816 4.9 32.10 2.786 12678 7 33.02 2.710 10467 5.8 33.94 2.639 12603 7 34.50 2.598 10964 6.1 35.69 2.513 8555 4.7 36.56 2.456 10659 5.9

Morphine sulfate Form γ is a unique crystalline phase. Morphine sulfate Form γ may be characterized as a white to off-white powder. Morphine sulfate Form γ is further characterized by its X-ray powder diffraction pattern peaks and/or d-spacing values, as listed in Table 3 below. FIG. 4 is a representative X-ray powder diffractogram for a representative sample of morphine sulfate Form γ made according to Example 6.

TABLE 3 XRPD peak list of Form γ 2θ d spacing, A° Count % 7.453 11.852 14058 7.6 8.455 10.450 30831 16.6 9.269 9.534 24458 13.2 10.115 8.738 26802 14.4 10.333 8.554 22449 12.1 11.274 7.842 13683 7.4 11.716 7.547 14746 7.9 12.049 7.340 21602 11.6 12.457 7.100 63642 34.3 12.804 6.908 58128 31.3 13.214 6.695 150759 81.2 13.811 6.407 40814 22 14.284 6.195 185710 100 14.826 5.970 46595 25.1 15.176 5.834 46458 25 15.627 5.666 110758 59.6 16.174 5.476 52472 28.3 16.445 5.386 80017 43.1 16.95 5.227 122648 66 17.467 5.073 119559 64.4 18.363 4.828 28359 15.3 18.852 4.703 59796 32.2 19.542 4.539 16054 8.6 20.129 4.408 36101 19.4 20.577 4.313 67254 36.2 21.291 4.170 21516 11.6 21.989 4.039 29706 16 22.549 3.940 42588 22.9 22.869 3.885 57195 30.8 23.329 3.810 33391 18 23.871 3.725 53918 29 24.101 3.690 30277 16.3 24.68 3.604 29904 16.1 24.903 3.573 47681 25.7 25.157 3.537 35556 19.1 25.758 3.456 30234 16.3 26.09 3.413 26587 14.3 26.474 3.364 15218 8.2 26.992 3.301 24641 13.3 27.243 3.271 19820 10.7 27.944 3.190 18586 10 28.632 3.115 15926 8.6 29.37 3.039 15433 8.3 29.953 2.981 20227 10.9 30.801 2.901 13006 7 31.443 2.843 18739 10.1

Morphine sulfate Form δ is a unique crystalline phase. Morphine sulfate Form δ may be characterized as a white to off-white powder. Morphine sulfate Form δ is further characterized by its X-ray powder diffraction pattern peaks and/or d-spacing values, as listed in Table 4 below. FIG. 5 is a representative X-ray powder diffractogram for a representative sample of morphine sulfate Form δ made according to Example 7.

TABLE 4 XRPD peak list of Form δ 2θ d spacing, A° Count % 5.70 15.486 23544 13.3 8.54 10.344 7313 4.1 9.43 9.368 5049 2.9 10.50 8.416 8086 4.6 11.34 7.799 48561 27.5 13.37 6.615 37282 21.1 13.76 6.432 27356 15.5 14.37 6.159 13851 7.8 15.39 5.754 44927 25.4 15.68 5.646 176656 100 16.20 5.466 23125 13.1 17.03 5.203 77012 43.6 17.54 5.051 58036 32.9 17.87 4.961 14950 8.5 19.55 4.537 7832 4.4 20.14 4.406 18108 10.3 20.64 4.299 52029 29.5 21.15 4.198 20217 11.4 21.99 4.03875 10728 6.1 22.427 3.96113 16914 9.6 22.66 3.92087 16607 9.4 24.001 3.70482 22324 12.6 24.169 3.6794 24531 13.9 24.873 3.57683 27399 15.5 25.184 3.53337 17641 10 25.71 3.46233 17253 9.8 26.202 3.39833 51837 29.3 26.659 3.34116 16594 9.4 27.052 3.2935 41688 23.6 27.477 3.24353 9229 5.2 28.06 3.17744 8234 4.7 28.488 3.13069 8906 5 29.37 3.03856 15075 8.5 30.03 2.97327 11893 6.7 31.512 2.83673 6770 3.8 32.238 2.77452 12699 7.2 33.137 2.70129 5857 3.3 34.866 2.57114 5473 3.1 35.732 2.51081 5019 2.8 36.913 2.43317 7795 4.4 37.581 2.39145 8745 5 38.562 2.33282 5063 2.9 39.5 2.27953 5249 3

Morphine sulfate Form ε is a unique crystalline phase. Morphine sulfate Form ε may be characterized as a white to off-white powder. Morphine sulfate Form ε is further characterized by its X-ray powder diffraction pattern peaks and/or d-spacing values, as listed in Table 5 below. FIG. 6 is a representative X-ray powder diffractogram for a representative sample of morphine sulfate Form ε made according to Example 8.

TABLE 5 XRPD peak list of Form ε 2θ d spacing, A° Count % 9.59 9.216 49596 27.5 10.80 8.189 58820 32.6 11.03 8.012 28976 16 12.01 7.362 10490 5.8 12.41 7.125 8694 4.8 13.54 6.535 56197 31.1 14.40 6.145 180610 100 14.98 5.911 7730 4.3 15.79 5.608 15043 8.3 16.44 5.389 54987 30.4 16.67 5.313 30704 17 17.22 5.144 4957 2.7 17.78 4.984 3188 1.8 18.77 4.723 32612 18.1 19.20 4.620 56708 31.4 19.92 4.453 16250 9 20.38 4.355 36651 20.3 21.42 4.145 21869 12.1 22.01 4.036 50499 28 22.59 3.934 5792 3.2 22.94 3.874 7766 4.3 23.58 3.770 121785 67.4 24.29 3.661 5575 3.1 24.87 3.577 13138 7.3 25.44 3.498 9570 5.3 26.08 3.414 16116 8.9 26.73 3.333 8477 4.7 27.10 3.288 5473 3 27.78 3.209 7022 3.9 28.09 3.174 17147 9.5 28.66 3.113 13869 7.7 28.87 3.090 15599 8.6 29.73 3.003 18568 10.3 30.35 2.942 6191 3.4 31.08 2.876 7841 4.3 31.87 2.806 4392 2.4 32.82 2.726 6976 3.9 33.03 2.710 8059 4.5 33.48 2.674 8999 5 34.77 2.578 13351 7.4 36.18 2.481 3929 2.2 36.93 2.432 5783 3.2 37.50 2.396 8307 4.6 37.93 2.370 4888 2.7 38.76 2.321 4425 2.4 39.26 2.293 3838 2.1 39.72 2.267 3764 2.1

Morphine sulfate Form ζ is a unique crystalline phase. Morphine sulfate Form ζ may be characterized as a white to off-white powder. Morphine sulfate Form ζ is further characterized by its X-ray powder diffraction pattern peaks and/or d-spacing values, as listed in Table 6 below. FIG. 7 is a representative X-ray powder diffractogram for a representative sample of morphine sulfate Form ζ made according to Example 9.

TABLE 6 XRPD peak list of Form ζ 2θ d spacing, A° Count % 5.83 15.145 67066 37.9 10.53 8.397 67455 38.1 11.61 7.613 64699 36.6 12.03 7.353 18553 10.5 13.37 6.617 16740 9.5 13.67 6.475 131887 74.5 14.28 6.198 177010 100 15.68 5.646 139905 79 17.03 5.203 29597 16.7 17.45 5.078 13720 7.8 17.76 4.989 42869 24.2 18.93 4.685 17523 9.9 20.44 4.342 148314 83.8 21.28 4.173 5956 3.4 21.89 4.056 47000 26.6 22.24 3.995 24366 13.8 22.86 3.888 31247 17.7 23.30 3.815 22223 12.6 24.24 3.668 118902 67.2 24.89 3.575 10814 6.1 25.56 3.482 28441 16.1 26.39 3.374 67762 38.3 26.81 3.323 5745 3.2 27.52 3.239 35467 20 28.44 3.136 17251 9.7 28.87 3.091 20379 11.5 29.26 3.049 12317 7 30.08 2.968 5088 2.9 30.52 2.927 18570 10.5 31.22 2.862 6028 3.4 31.62 2.827 14302 8.1 31.88 2.805 8467 4.8 32.39 2.762 12007 6.8 33.42 2.679 3102 1.8 33.93 2.640 28295 16 34.59 2.591 5340 3 35.08 2.556 10972 6.2 36.49 2.460 11523 6.5 36.92 2.433 7022 4 37.62 2.389 4998 2.8 38.25 2.351 3796 2.1 38.89 2.314 5009 2.8 39.24 2.294 5205 2.9 39.80 2.263 6548 3.7

Morphine sulfate Form η is a unique crystalline phase. Morphine sulfate Form η may be characterized as a white to off-white powder. Morphine sulfate Form η is further characterized by its X-ray powder diffraction pattern peaks and/or d-spacing values, as listed in Table 7 below. FIG. 8 is a representative X-ray powder diffractogram for a representative sample of morphine sulfate Form η made according to Example 10.

TABLE 7 XRPD peak list of Form η 2θ d spacing, A° Count % 7.75 11.405 4463 15 9.16 9.643 2920 9.8 10.71 8.258 1812 6.1 12.46 7.100 2817 9.5 12.87 6.875 11111 37.3 13.15 6.727 11390 38.3 13.52 6.545 8090 27.2 13.88 6.374 7809 26.2 14.36 6.162 26492 89 14.87 5.952 3086 10.4 15.49 5.717 29771 100 16.42 5.394 18857 63.3 16.68 5.311 7777 26.1 17.19 5.156 10816 36.3 17.36 5.103 9882 33.2 18.33 4.835 14720 49.4 19.37 4.580 5087 17.1 19.83 4.473 4094 13.8 20.14 4.405 2502 8.4 20.54 4.320 6772 22.7 20.97 4.234 4808 16.2 21.27 4.175 7703 25.9 21.51 4.128 9621 32.3 21.96 4.045 13770 46.3 22.44 3.959 5453 18.3 22.73 3.909 3857 13 23.09 3.848 4832 16.2 23.31 3.813 8138 27.3 23.88 3.723 10490 35.2 24.81 3.585 2936 9.9 25.12 3.542 6737 22.6 25.70 3.463 5827 19.6 25.88 3.440 6250 21 26.21 3.397 4614 15.5 26.64 3.344 5066 17 27.20 3.276 4950 16.6 27.93 3.192 3596 12.1 28.89 3.088 7990 26.8 30.03 2.974 3414 11.5 31.43 2.844 4953 16.6 32.98 2.713 2238 7.5 35.52 2.525 3025 10.2 39.21 2.296 2068 6.9

Morphine sulfate Form θ is a unique crystalline phase. Morphine sulfate Form θ may be characterized as a white to off-white powder. Morphine sulfate Form θ is further characterized by its X-ray powder diffraction pattern peaks and/or d-spacing values, as listed in Table 8 below. FIG. 9 is a representative X-ray powder diffractogram for a representative sample of morphine sulfate Form θ made according to Example 11.

TABLE 8 XRPD peak list of Form θ 2θ d spacing, A° Count % 4.17 4.172 44.5 0.1 4.27 4.269 36.4 0.1 6.20 6.197 4012 7.3 10.56 10.556 5607 10.2 11.00 11.001 8375 15.3 12.36 12.359 33350 60.8 13.18 13.180 7125 13 14.05 14.050 54408 99.2 14.22 14.215 54834 100 15.33 15.328 599 1.1 15.81 15.812 4672 8.5 16.26 16.255 28665 52.3 16.90 16.897 15956 29.1 17.73 17.726 13145 24 18.72 18.716 5306 9.7 19.03 19.026 9348 17 20.12 20.118 828 1.5 20.73 20.733 31446 57.3 21.38 21.376 2555 4.7 22.04 22.037 2930 5.3 22.74 22.742 17287 31.5 23.11 23.109 6983 12.7 24.14 24.138 1040 1.9 24.54 24.538 1670 3 24.99 24.990 9728 17.7 25.25 25.247 13894 25.3 25.56 25.561 5572 10.2 25.92 25.923 15440 28.2 26.50 26.496 2590 4.7 27.40 27.402 1552 2.8 27.75 27.752 4031 7.4 28.03 28.025 3130 5.7 28.59 28.592 6237 11.4 29.34 29.335 1363 2.5 29.98 29.979 2835 5.2 30.85 30.848 2642 4.8 31.12 31.121 4001 7.3 31.96 31.961 1156 2.1 32.82 32.815 2220 4 33.55 33.549 2879 5.3 34.52 34.515 634 1.2 35.48 35.477 1388 2.5 36.01 36.005 2078 3.8 36.75 36.752 441 0.8 37.65 37.653 1361 2.5 38.53 38.534 475 0.9 39.84 39.838 946 1.7

Differential scanning calorimetry is performed using a TA Instruments Q10 DSC. Typically, samples are placed in unsealed, covered hermetic alodined aluminum sample pans and scanned from about 30° C. to about 300° C. at a rate of about 10° C./min under a nitrogen purge of about 50 mL/min.

Differential scanning calorimetry is performed on representative samples of morphine sulfate Forms α, β, γ, δ, ε, ζ, η and θ, as shown in FIGS. 11, 12, 13, 14, 15, 16, 17 and 18, respectively. Two thermal events may be observed in the differential scanning calorimetry thermogram for morphine sulfate Form α at about 117° C. and about 173° C. Two thermal events may be observed in the differential scanning calorimetry thermogram for morphine sulfate Form β at about 112° C. and about 177° C. Two thermal events may be observed in the differential scanning calorimetry thermogram for morphine sulfate Form γ at about 140° C. and about 234° C. Three thermal events may be observed in the differential scanning calorimetry thermogram for morphine sulfate Form δ at about 58° C., 136° C. and about 221° C. One thermal event may be observed in the differential scanning calorimetry thermogram for morphine sulfate Form ε at about 160° C. Two thermal events may be observed in the differential scanning calorimetry thermogram for morphine sulfate Form ζ at about 163° C. and about 238° C. One thermal event may be observed in the differential scanning calorimetry thermogram for morphine sulfate Form η at about 284° C. Two thermal events may be observed in the differential scanning calorimetry thermogram for morphine sulfate Form θ at about 158° C. and about 237° C.

The present disclosure also describes pharmaceutical compositions comprising one or more of the morphine sulfate crystalline forms as herein described in association with conventional excipients, i.e., pharmaceutically acceptable organic or inorganic carrier substances. These compositions may be in dosage forms such as, but not limited to, tablets, pills, capsules, powders, granules, sterile parenteral solutions or suspensions, metered aerosol or liquid sprays, drops, ampoules, autoinjector devices or suppositories; for oral, parenteral, intranasal, sublingual or rectal administration, or for administration by inhalation or insufflation.

To prepare a pharmaceutical composition of the present disclosure, any one or more of the morphine sulfate crystalline forms as herein described is intimately admixed with a pharmaceutical excipient according to conventional pharmaceutical compounding techniques, which excipient may take a wide variety of forms depending of the form of preparation desired for administration (e.g. oral or parenteral). Suitable pharmaceutically acceptable excipients include those known in the art and those yet to be discovered. Descriptions of some of these pharmaceutically acceptable excipients may be found in The Handbook of Pharmaceutical Excipients and the Pharmaceutical Society of Great Britain. The pharmaceutical compositions of the present disclosure may be prepared according to any method known in the art as well as yet to be discovered improvements thereto. Methods of formulating pharmaceutical compositions have been described in numerous publications such as Pharmaceutical Dosage Forms: Tablets, Second Edition, Revised and Expanded, Volumes 1-3; Pharmaceutical Dosage Forms: Parenteral Medications, Volumes 1-2; and Pharmaceutical Dosage Forms: Disperse Systems, Volumes 1-2.

The oral formulations of the present disclosure may be coated or otherwise compounded to provide a dosage form affording the advantage of prolonged action. The sustained release dosage forms may optionally comprise particles containing any one or more of the morphine sulfate forms as herein described. Preferably, the particles are film coated with a material that permits release of the active at a sustained rate in an aqueous medium. The film coat is chosen so as to achieve, in combination with the other stated properties, desired release properties. The sustained release coating formulations of the present disclosure should preferably be capable of producing a strong, continuous film that is smooth and elegant, capable of supporting pigments and other coating additives, non-toxic, inert and tack-free. The sustained release formulations of the present disclosure preferably slowly release the active agent(s), e.g., when ingested and exposed to gastric fluids, and then to intestinal fluids. For example, the tablet or pill can comprise an inner dosage and an outer dosage component, the latter being in the form of an envelope over the former. The two components can be separated by an enteric layer which serves to resist disintegration in the stomach and permits the inner component to pass intact into the duodenum or to be delayed in release. A variety of materials can be used for such enteric layers or coatings, such materials including a number of polymeric acids with such materials as shellac, cetyl alcohol and cellulose acetate. Sustained release dosage forms according to the present disclosure may also be prepared as osmotic dosage formulations known in the art as well as improvements thereto.

The liquid forms in which the novel compositions of the present disclosure may be incorporated for administration orally or by injectable include, aqueous solutions, suitably flavored syrups, aqueous or oil suspensions, and flavored emulsions with edible oils as well as elixirs and similar pharmaceutical vehicles. The liquid forms may include suitably flavored suspending or dispersing agents such as the synthetic and natural gums. For parenteral administration, sterile suspensions and solutions are desired. Isotonic preparations which generally contain suitable preservative are employed when intravenous administration is desired.

The formulations of the present disclosure may be formulated as a pharmaceutical suppository for rectal administration comprising a suitable suppository base, and any one or more of the morphine sulfate crystalline forms as herein described. This includes the preparation of sustained release suppository formulations as described in U.S. Pat. No. 5,215,758.

The compounds of the present disclosure may be administered in intranasal form via topical use of suitable intranasal vehicles, or via transdermal skin patches well known to those of ordinary skill in the art. To be administered in the form of a transdermal delivery system, the dosage administration will be continuous rather than intermittent throughout the dosage regimen.

The present disclosure provides for a method of treating pain by administering to a subject in need thereof the dosage forms described above which contain any one or more of the morphine sulfate crystalline forms as herein described. The dosage of the products may be varied over a wide range. Optimal dosages and dosage regimens to be administered may be readily determined by those skilled in the art, and will vary with the mode of administration, the strength of the preparation and the advancement of the disease condition. In addition, factors associated with the particular subject being treated, including subject's sex, age, weight, diet, physical activity, time of administration and concomitant diseases, will result in the need to adjust dosages and/or regimens.

EXAMPLES

The disclosure is illustrated by the following examples.

The following examples are set forth to aid in the understanding of the disclosure, and are not intended and should not be construed to limit in any way the disclosure set forth in the claims which follow thereafter. Although illustrated and herein described with reference to certain specific embodiments, the present disclosure is nevertheless not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the spirit of the disclosure.

Example 1 Preparation of Morphine Sulfate

Morphine Technical Alkaloid (MTA) material is combined with water and 0.5 equiv. of 50% isopropyl acetate diluted sulfuric acid. The mixture is heated to about 75° C. and cooled to about 15° C. at a rate of about 0.23° C. per minute. The resulting mixture is filtered under vacuum and washed with ethanol. The filtrate is dried at about 50° C. under vacuum. The resulting solids are determined to be morphine sulfate.

Example 2 Preparation of Morphine Free Base

About 8.43 g of morphine sulfate and about 40 mL of water are added to an Easy Max™ set at 350 RPM agitation rate. The mixture becomes clear and is then heated to about 65° C. The pH is checked and determined to be about 5. About 10 mL of pre-made solution in water of 1 M NaOH is added to the mixture. Solids are formed. About 5 mL of pre-made solution in water of 1 M NaOH is added to the mixture. The pH is checked and determined to be about 6. A few NaOH pellets are added to the mixture. Heating and stirring is continued for about 2 hours. The mixture is then cooled to about 50° C., filtered under vacuum filtration and washed several times with water. The pH of the filtrate is checked and determined to be about 13. The filtrate is dried at about 45° C. under vacuum for about 12-24 hours. The resulting solids are analyzed by X-ray powder diffraction and determined to be morphine free base.

Example 3 Preparation of Form α Using Acetone

About 200 mg of morphine free base and about 1 mL of acetone are added to a vial. Concentrated sulfuric acid is pre-diluted in isopropanol. About 49 μL of 50% isopropyl acetate diluted sulfuric acid is added to the vial. The mixture is stirred for about 4 to 5 hours at about 20 to 26° C. The resulting slurry is analyzed by X-ray powder diffraction and determined to be morphine sulfate Form α.

Example 4 Preparation of Form α Using Water

About 200 mg of morphine free base and about 1 mL of water are added to a vial. Concentrated sulfuric acid is pre-diluted in isopropanol. About 49 μL of 50% isopropyl acetate diluted sulfuric acid is added to the vial. The mixture is stirred for about 4 to 5 hours at about 55 to 65° C. The resulting solids are analyzed by X-ray powder diffraction and determined to be morphine sulfate Form α.

Example 5 Preparation of Form β Using Isopropyl Acetate

About 200 mg of morphine free base and about 1 mL of isopropyl acetate are added to a vial. Concentrated sulfuric acid is pre-diluted in isopropanol. About 49 μL of 50% isopropyl acetate diluted sulfuric acid is added to the vial. The mixture is stirred for about 4 to 5 hours at about 20 to 26° C. The resulting solids are analyzed by X-ray powder diffraction and determined to be morphine sulfate Form β.

Example 6 Preparation of Form γ Using Acetone

About 200 mg of morphine free base and about 1 mL of acetone are added to a vial. Concentrated sulfuric acid is pre-diluted in isopropanol. About 49 μL of 50% isopropyl acetate diluted sulfuric acid is added to the vial. The mixture is stirred for about 4 to 5 hours at about 55 to 65° C. The resulting solids are analyzed by X-ray powder diffraction and determined to be morphine sulfate Form γ.

Example 7 Preparation of Form δ Using Ethanol

About 200 mg of morphine free base and about 1 mL of ethanol are added to a vial. Concentrated sulfuric acid is pre-diluted in isopropanol. About 49 μL of 50% isopropyl acetate diluted sulfuric acid is added to the vial. The mixture is stirred for about 4 to 5 hours at about 20 to 26° C. The resulting solids are analyzed by X-ray powder diffraction and determined to be morphine sulfate Form δ.

Example 8 Preparation of Form ε Using Methanol

About 200 mg of morphine free base and about 1 mL of methanol are added to a vial. Concentrated sulfuric acid is pre-diluted in isopropanol. About 49 μL of 50% isopropyl acetate diluted sulfuric acid is added to the vial. The mixture is stirred for about 4 to 5 hours at about 20 to 26° C. The resulting solids are analyzed by X-ray powder diffraction and determined to be morphine sulfate Form ε.

Example 9 Preparation of Form ζ Using Water

About 200 mg of morphine free base and about 1 mL of water are added to a vial. Concentrated sulfuric acid is pre-diluted in isopropanol. About 49 μL of 50% isopropyl acetate diluted sulfuric acid is added to the vial. The mixture is stirred for about 4 to 5 hours at about 20 to 26° C. The resulting solids are analyzed by X-ray powder diffraction and determined to be morphine sulfate Form ζ.

Example 10 Preparation of Form η Using Ethanol/Methanol

About 200 mg of morphine free base and about 1 mL of ethanol/methanol 80:20 are added to a vial. Concentrated sulfuric acid is pre-diluted in isopropanol. About 49 μL of 50% isopropyl acetate diluted sulfuric acid is added to the vial. The mixture is stirred for about 4 to 5 hours at about 20 to 26° C. The resulting solids are analyzed by X-ray powder diffraction and determined to be morphine sulfate Form η.

Example 11 Preparation of Form θ Using Water

About 5 mg of MTA material, about 11 mL of water and a 50% solution of about 0.7 sulfuric acid equiv. are heated to about 70° C. The mixture is cooled at a rate of about 1.05° C. per minute with fast agitation (about 800 RPM) over about 2.5 hours. The resulting solids are analyzed by X-ray powder diffraction and determined to be morphine sulfate Form θ. 

What is claimed is:
 1. A method of making morphine sulfate Form α comprising exposing a starting material comprising morphine free base to acetone and a composition comprising sulfuric acid at a temperature in the range of about 20 to 26° C. for a time sufficient to yield morphine sulfate Form α, wherein Form α has an X-ray powder diffraction pattern comprising peaks, in terms of 2-theta, at about 15.71 and about 17.08.
 2. A method of making morphine sulfate Form α comprising exposing a starting material comprising morphine free base to water and a composition comprising sulfuric acid at a temperature in the range of about 55 to 65° C. for a time sufficient to yield morphine sulfate Form α, wherein Form α has an X-ray powder diffraction pattern comprising peaks, in terms of 2-theta, at about 15.71 and about 17.08.
 3. A method of making morphine sulfate Form β comprising exposing a starting material comprising morphine free base to isopropyl acetate and a composition comprising sulfuric acid at a temperature in the range of about 20 to 26° C. for a time sufficient to yield morphine sulfate Form β, wherein Form β has an X-ray powder diffraction pattern comprising peaks, in terms of 2-theta, at about 15.43 and about 17.78.
 4. A method of making morphine sulfate Form γ comprising exposing a starting material comprising morphine free base to acetone and a composition comprising sulfuric acid at a temperature in the range of about 55 to 65° C. for a time sufficient to yield morphine sulfate Form γ, wherein Form γ has an X-ray powder diffraction pattern comprising peaks, in terms of 2-theta, at about 14.28 and about 13.21.
 5. A method of making morphine sulfate Form δ comprising exposing a starting material comprising morphine free base to ethanol and a composition comprising sulfuric acid at a temperature in the range of about 20 to 26° C. for a time sufficient to yield morphine sulfate Form δ, wherein Form δ has an X-ray powder diffraction pattern comprising peaks, in terms of 2-theta, at about 15.68 and about 17.03.
 6. A method of making morphine sulfate Form ε comprising exposing a starting material comprising morphine free base to methanol and a composition comprising sulfuric acid at a temperature in the range of about 20 to 26° C. for a time sufficient to yield morphine sulfate Form ε, wherein Form ε has an X-ray powder diffraction pattern comprising peaks, in terms of 2-theta, at about 14.40 and about 23.58.
 7. A method of making morphine sulfate Form ζ comprising exposing a starting material comprising morphine free base to water and a composition comprising sulfuric acid at a temperature in the range of about 20 to 26° C. for a time sufficient to yield morphine sulfate Form ζ, wherein Form ζ has an X-ray powder diffraction pattern comprising peaks, in terms of 2-theta, at about 14.28 and about 20.44.
 8. A method of making morphine sulfate Form η comprising exposing a starting material comprising morphine free base to an ethanol/methanol mixture and a composition comprising sulfuric acid at a temperature in the range of about 20 to 26° C. for a time sufficient to yield morphine sulfate Form η, wherein Form η has an X-ray powder diffraction pattern comprising peaks, in terms of 2-theta, at about 15.49 and about 14.36.
 9. A method of making morphine sulfate Form θ comprising exposing a starting material comprising morphine to water and a composition comprising sulfuric acid at a temperature in the range of about 65 to 75° C. for a time sufficient to yield morphine sulfate Form θ, wherein Form θ has an X-ray powder diffraction pattern comprising peaks, in terms of 2-theta, at about 14.22 and about 14.05. 